NAVISTAR TMS-7125-2011 Composite Trim Panels.pdf

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1、This document is restricted and may not be sent outside Navistar, Inc. reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2011 by Navistar, Inc. JUNE 2011 Page 1 of 6 NAVISTAR, INC. TMS (TRUCK MATERIAL SPECIFICATION) NUMBER: TMS-7

2、125 srr TITLE: Composite Trim Panels CURRENT REV No.: 1106 DATE: June 2011 WRITTEN/EDITED BY: Materials Engineering APPROVED BY: Materials Engineering SUPERSEDES: Rev 1004 April 2010 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REVISION This specification may involve hazardous materi

3、als, equipment, and procedures. This specification does not purport to address all of the safety issues associated with its use. The user is responsible to consult appropriate safety and health practices and to determine the applicability of regulatory limits prior to use. Change Notice: Added Type

4、VIII; editorial changes. Reference: Files: 16-7; 30-14F Keywords: Trim, interior trim, plastic composites, plastic trim 1.0 APPLICATION This specification covers requirements for seven types of composite trim panels used in interior applications in NAVISTAR trucks. 2.0 SCOPE This specification cover

5、s the general, durability, performance, design, quality, qualification, shipping and identification, and source approval requirements for composite trim panels. 2.1 Restricted Chemical Substances Effective January 1, 2007, all product supplied to the requirements of this specification must comply wi

6、th the requirements of the CEMS B-50 specification 3.0 REFERENCE DOCUMENTS Unless otherwise specified the latest issue of all referenced standards shall apply. The following Specifications, Standards, and Regulations are referenced in this specification. Quality System Standard ISO 9001 or TS-16949

7、AATCC Method 30 NAVISTAR Manufacturing Std. MS-D-13 ASTM D 638 NAVISTAR NV-2C1 ASTM D 751 CFR Title 29, Part 1910 ASTM D 790 NAVISTAR TMS-6505 ASTM D 1037 NAVISTAR TMS-7028 ASTM D 2240 NAVISTAR TMS-7113 ASTM D 3029 NAVISTAR TMS-7121 ASTM D 5587 NAVISTAR TMS-7126 SAE J315 NAVISTAR TMS-9543 SAE J1885

8、NAVISTAR TMS-9544 ASTM C 384 NAVISTAR CEMS GT-31 NAVISTAR CEMS B-50 4.0 GENERAL REQUIREMENTS Individual components of the trim composite/assembly will meet all requirements of the material specification(s) indicated on the engineering drawing for that component and/or subassembly, in addition to mee

9、ting all requirements of this specification. Foam used in the internal construction will NUMBER: TMS-7125 TITLE Composite Trim Panels REVISION: 1106 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers a

10、re required to assume all patent liability. 2011 by Navistar, Inc. JUNE 2011 Page 2 of 6 comply with TMS-6505 Type I, density 24 kg/m minimum. Facing materials shall be specified on the engineering print but are usually covered by sections of TMS-7113 for fabrics; TMS-7121 for vinyls; and TMS-7126 f

11、or carpets and non-woven materials. The minimum physical properties of the base supporting material are listed in Table 1. 4.1 Composition A description of the composition of each of the types of composite panel is provided herein. 4.1.1 Type I: is a rigid cellulosic molded base. 4.1.2 Type II: is a

12、 rigid, molded wood fiber based product that uses polypropylene as a binder. This type is suitable for use as side and back panels. 4.1.3 Type III: is a semi-rigid molded material that is a combination of natural fibers and thermoplastic binders mixed into needled mats. 4.1.4 Type IV: is a molded ma

13、terial that is a combination of urethane foam and fiberglass scrim with a backing that may be rigid if required. This type is suitable for use as a headliner. Formerly TMS-7117. The composite may consist of the following layers: 4.1.4.1 Backing Material 4.1.4.2 Fiberglass mat (in designated areas) 4

14、.1.4.3 “Firm“ foam 4.1.4.4 Fiberglass mat (in designated areas) 4.1.4.5 Backing material 4.1.4.6 “Soft“ foam 4.1.5 Type V: A molded laminate that is a combination of urethane resin, fiberglass reinforcement, polyester batting, and scrim. This type is suitable for use as a headliner. Formerly TMS-711

15、7. The composite may consist of the following layers: 4.1.5.1 Cover Material 4.1.5.2 Fiberglass Reinforcement 4.1.5.3 Resinated Polyester Batting 4.1.5.4 Fiberglass Reinforcement 4.1.5.5 Scrim 4.1.6 Type VI: A rigid urethane foam molded in conjunction with a continuous strand glass mat. This type is

16、 suitable for use in door trim and B-pillars. 4.1.7 Type VII: A polyurethane elastomeric molded soft skin that consists of an aliphatic urethane in mold coating followed by an aromatic solid urethane skin with a urethane foam injected between the skin and a plastic substrate. This type is suitable f

17、or use as an instrument panel trim cover. 4.1.8 Type VIII: A thermoplastic composite of polypropylene and long glass chopped fibers. Substrate is sandwiched between outer layers of scrim and adhesive film. Composite is adhered to a foam-backed vinyl through compression molding. This type is suitable

18、 for use as headliner, back panels and B-pillars. 4.2 Performance Requirements 4.2.1 Impact Resistance Test panels mounted in an appropriate fixture shall withstand a minimum impact of 3.9 J (3.0 ft/lbs) without significant damage or cracking. The sample(s) exposed in the dimensional stability test

19、should be returned to the cold chamber at 30 2 C (-22 5 F) for 4 hours and tested immediately upon removal. NUMBER: TMS-7125 TITLE Composite Trim Panels REVISION: 1106 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Sta

20、ndards. Suppliers are required to assume all patent liability. 2011 by Navistar, Inc. JUNE 2011 Page 3 of 6 4.2.2 Dimensional Stability Test panels mounted in/on an appropriate test fixture shall withstand 2 complete cycles of the environmental test indicated below, without exhibiting objectionable

21、distortion, color or gloss change, odor, warping, sag, staining, or delamination. Dimensional changes shall not be greater than tolerances indicated on the part/assembly drawings. Test panels shall be examined after completion of the environmental test and again after a two hour recovery period. 4.2

22、.3 Environmental Test Cycle: 4.2.3.1 16 hours at 95 5% R.H. at 38 2 C (100 5 F) 4.2.3.2 2 hours at ambient condition 4.2.3.3 16 hours at 85 2 C (185 5 F) 4.2.3.4 2 hours at ambient condition 4.2.3.5 4 hours at 30 2 C (-22 5 F) 4.2.3.6 2 hours at ambient condition 4.2.4 Flammability The finished comp

23、osite must conform to and be certified to meet all requirements of FMVSS-302 and all requirements of TMS-9544. Components of the assembly/composite which are not 100% bonded together shall be tested separately and each component must demonstrate required flammability resistance. Components of the co

24、mposite which are 100% bonded together are not specifically required to demonstrate flammability resistance when tested separately as individual parts, however; the bonded composite must demonstrate the required flammability resistance. 4.2.5 Adhesion Parts shall meet the requirements of TMS-7028. 4

25、.2.6 Fastening and Handling The finished composite/assembly shall have sufficient strength/rigidity to permit handling in installation and service procedures without damage. Punched holes for mounting or retention purposes shall be free of loose fibers and/or frayed material. To prevent fraying in t

26、he hole-punched area, a heat process may be used to melt the frayed material and hold it in place. Any process used to accomplish this operation will not cause an objectionable appearance problem/defect. 4.2.7 Accelerated Weathering per CEMS GT-31, Zone A, Zone B or Zone C All materials shall qualif

27、y to one of the two following tests: 4.2.7.1 Xenon Arc: 4.2.7.1.1 Interior parts, per Method A 4.2.7.1.2 Interior parts, per Method F 4.2.7.2 Required (Either Method): There will be no sign of color alteration greater than a E of 3, decreased pliability or fiber degradation after exposure. A minimum

28、 rating of 3.0 per AATCC Evaluation Procedure 1. 4.2.8 Mildew Resistance: AATCC Method 30 Shall not exhibit any objectionable odor or growth of mildew. 4.2.9 Sound Absorption Headliners Only*: ASTM C 384 (NAVISTAR NV-2C1) The normal incidence sound absorption coefficients shall be measured at: 500,

29、630, 800, 1K, 1.25K, 1.6K, 2K, 2.5K, 3.1K, min normal abs coeff 0.40. The test method shall be ASTM C 384 (NAVISTAR NV-2C1). The headliner test sample shall be mounted in the sample holder in the same orientation and part NUMBER: TMS-7125 TITLE Composite Trim Panels REVISION: 1106 This document is r

30、estricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2011 by Navistar, Inc. JUNE 2011 Page 4 of 6 relationship as in the truck, with the back-plate of the sample holder represe

31、nting the roof sheet metal. If there is more than one typical air gap between the headliner and roof, test each frequency with each air gap and generate an average for each frequency based on the relative area of each air gap. * Note: This fully applies to Day Cab headliners only. Sleeper headliners

32、 shall be tested to this and the results reviewed and approved by NAVISTAR Global Engineering Noise, Vibration and Harshness Group. 5.0 QUALITY Material supplied shall be free from objectionable odor, be of uniform quality, and match the pattern, color, finish, and texture of pre production approved

33、 samples on file in the TDTC Industrial Design Department. Pre-production samples of material sufficient for complete test and evaluation should be submitted to TDTC Materials Engineering for approval. All samples shall be accompanied by a laboratory report per TMS-9543 showing conformance to all it

34、ems denoted in the specification(s). 5.1 Qualification Materials submitted for approval to this specification shall include the following: 5.1.1. A detailed, signed test report documenting testing to this specification per TMS-9543. 5.1.2. The complete procedure used for preparing and curing materia

35、ls for test, especially surface preparation (when appropriate) and condition of the test materials. 5.1.3. A complete description, including engineering prints and/or pictures, of any non-standard test fixtures used. 5.1.4. Adhesive, substrate and any chemicals used for bonding where appropriate. 5.

36、2 Submission The material and test report shall be submitted to: Manager of Materials Engineering Materials Engineering and Technology NAVISTAR, INC. PO Box 1109 Fort Wayne, IN 46801 5.3 Approval A report from NAVISTAR will be issued approving material to this specification. Approval is not granted

37、until this report has been published. Specification changes listing the approval may be delayed from the date of the original approval; this report is authorization of that approval prior to this change. 6.0 SOURCE APPROVAL AND QUALITY CONTROL 6.1 Supplier Requirements All suppliers to NAVISTAR are

38、required to be registered to ISO 9001 Quality System Requirements. NAVISTAR will also accept TS-16949 registration as long as the supplier can also fulfill all AIAG PPAP (Production Part Approval Process) documentation and approval requirements. Suppliers must maintain their certification with an ac

39、credited registrar and must furnish copies of registration certificates to their NAVISTAR Corporate Buyer upon request. 6.2 Approval Parts supplied against contracts or purchase orders citing this specification shall be equivalent in all respects to those samples that were approved by the purchaser.

40、 No changes in formulation or NUMBER: TMS-7125 TITLE Composite Trim Panels REVISION: 1106 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2011 by Navista

41、r, Inc. JUNE 2011 Page 5 of 6 processing practices are permitted without approval. In the event that changes in material, properties, processing practices, construction, color, or labeling of the product are required, the supplier shall notify Materials Engineering at TDTC and NAVISTAR Purchasing an

42、d Supplier Development of the proposed change(s). Test data indicating conformance to all requirements of this specification, test samples, and new or amended or updated Material Safety Data Sheet(s) (MSDS), in accordance with CFR Title 29, Part 1910 shall be submitted with the request for change. 6

43、.3 Process Control The supplier shall either perform and report results of tests on specific lots of parts produced using ISO 9001 or TS-16949 guidelines, or provide statistical evidence of the lot having been produced in a state of statistical control and with a process capable of providing all req

44、uired properties. The part supplier and the plant metallurgist and/or the quality control manager of the using NAVISTAR plant may determine testing and reporting requirements on specific products. 7.0 SHIPPING, PACKING AND IDENTIFICATION Shipping, packing and identification shall be in accordance wi

45、th Manufacturing Std. MS-D-13. 8.0 DESIGNATION ON DRAWINGS Composite Trim Panel per TMS-7125 Type I, II, III, IV, V, VI, VII, or VIII (as applicable) 9.0 TECHNICAL INFORMATION For further information related to the technical content of this specification, contact: Suppliers may purchase controlled c

46、opies of this specification by contacting: Materials Engineering and Technology Dept. Truck Development and Technology Center 2911 Meyer Road Fort Wayne, IN 46803 E-mail: MaterialsEngineeringN IHS Global Inc. 15 Inverness Way East Englewood CO 80112-5776 Phone: 1-800-854-7179 E-mail: AutomotiveIHS.c

47、om Website: http:/ NUMBER: TMS-7125 TITLE Composite Trim Panels REVISION: 1106 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2011 by Navistar, Inc. JUN

48、E 2011 Page 6 of 6 Table 1 Material Physical Properties Property Test Method Type I Type II Type III Type IV Type V Type VI Type VII (Skin) Type VII (Foam) Type VIII Nominal Thickness, mm 2.5 3.0 2.5 Specific Gravity ASTM D1037 0.95 1.07 0.50 1.01 Hardness - Shore D ASTM D2240 65 70 Shore A 71 Moist

49、ure Content, max % ASTM D1037 1.0 1.5 8.0 Water Absorption 2.5 hours max % 24 hours max % SAE J315 2.0 2.0 1.5 2.5 0.5 1.0 Tensile Strength, min MPa ASTM D638 15 MD- 17.4 AMD- 12.8 MD- 21.0 AMD- 13.0 19/15 15 8.7 6 Tensile Modulus, min GPa ASTM D638 1.7 MD- 2.5 AMD- 2.0 MD- 4.1 AMD- 1.0 2.2/1.5 650 Tensile Elongation, % ASTM D638 1.5 1.5 1 1.9 1 2.4/2.2 212 Flexural